Elastomeric polymers

ABSTRACT

Elastomeric block co-polyesters having improved elastic and work recovery properties, a high melting point and are stable at high temperatures, have hard segments comprising at least 50 mole percent of polyethylene terephthalate groups and soft segments comprising at least 40 weight percent of the block copolyester. The soft segments, which have a defined structure, are formed by reacting phenolic compounds with a mixture of ethylene oxide and propylene oxide/butylene oxide.

This invention relates to elastomeric block copolyesters having improved properties.

It is well known that elastomeric articles such as fibres and tapes may be formed by melt extruding block copolyesters comprising "hard" segments of crystallisable polyester units and "soft" segments of amorphous units. Soft segments formed from high molecular weight poly(oxyalkylene) glycols, e.g. those derived from ethylene oxide, propylene oxide, and butylene oxide, have been shown to be quite effective. It is known from U.S. Pat. No. 4,467,595 that the introduction into the poly(oxyalkylene) chain of a "foreign repeat unit" which is greatly different from poly(oxyalkylene) disrupts the chain regularity, so reducing the chance of crystallisation of the soft segment, thereby allowing the use of high molecular weight polyglycols as soft segment. The use of a higher molecular weight soft segment gives rise to several advantages, including raising the melting point of the block copolymer, higher tenacity, and improved elastomeric performance. The "foreign repeat unit" of the soft segments are derived from heterocyclic, nitrogen-containing compounds, e.g. derivatives of hydantoin, oxadiazole, thiadiazole, imidazole and hypoxanthine.

Japanese Patent No. 58-18412 discloses an elastomeric block copolyester fibre having improved heat resistance. The soft segments of this polyester are formed from polymers prepared by condensing an alkylene oxide with a bisphenol to give a product having an average molecular weight between 800 and 20,000 and in which the mean number of bisphenol units is between 2 and 20. The block copolyesters comprise between 3 and 60% by weight of the polyalkylene oxide.

The elastomeric block copolyesters disclosed in Japanese Patent No. 58-18412 are not entirely satisfactory for the production of commercially acceptable products such as cushions, mouldings, gaskets, fibres and tapes.

We have found that improved products can be obtained from elastomeric block copolyesters in which the soft segments each comprise a single bisphenol group onto which is condensed a combination of ethylene oxide and propylene oxide and/or butylene oxide. In particular we have been able to produce elastomeric fibres and tapes which have a high melting point (i.e. above 200° C.), are stable at high temperatures, and, above all, have good elastic and work recovery properties.

Therefore, according to one aspect of the present invention there is provided an elastomeric block co-polyester comprising hard and soft segments, characterised in that the hard segments comprise at least 50 mole percent of polyethylene terephthalate groups, and the soft segments, comprise at least 40 weight percent of the block co-polyester and have the structure ##STR1## where (i) X represents a direct link between the phenyl groups, ##STR2## (ii) Y represents a combination of --[--CH₂ --CH₂ --O--] (I) with ##STR3## the ratio of (I) to (II)+(III) being within the range 10:1 and 1:20, (iii) m and n each represent an integer, the sum of which corresponds to the segment having a molecular weight of 500 to 10,000,

(iv) R₁₋₈ each represent --H, --CH₃, --C₂ H₅, or --C₃ H₇,

(v) R₉₋₁₀ each represent --H, --CH₃ --C₂ H₅, --C₃ H₇, ##STR4## and (vi) q represents an integer selected from 0, 1, 2 and 3.

For elastomeric block copolymers which are to be converted into fibres, it is preferable that the soft segments should comprise at least 50, and preferably at least 60 weight percent of the copolyester. However the soft segments may comprise up to 70 to 75 weight percent of the copolyester. For those copolymers which are to be converted into tapes, it is preferable that the soft segments should comprise at least 50, and preferably about 65 weight percent of the copolyester.

Preferably the hard segments are formed entirely from polyethylene terephthalate groups, but they may contain other groups derived from isophthalic acid, adipic acid, sebacic acid, 2,6- and 2,7-naphthoic acids, or mixtures thereof. The hard segments may also comprise a block copolymer of polyethylene and polybutylene terephthalate. Where the elastomeric block copolymer is to be used for the production of fibres and tapes, it is desirable that these other groups should not exceed 25 mole percent of the hard segments, but for the production of cushions, mouldings, gaskets and the like, these other groups may be present up to 50 mole percent of the hard segments.

The soft segments may be formed by condensing ethylene oxide, propylene oxide and/or 1,2 butylene oxide, either separately and sequentially or as a mixture, with a dihydroxyphenol, for example resorcinol, or a bisphenol. Suitable bisphenols include the group having the structure ##STR5## where X represents a direct link between the phenyl groups, ##STR6## R₁₋₈ represent --H, --CH₃, --C₂ H₅, or --C₃ H₇,

R₉₋₁₀ represent --H, --CH₃, --C₂ H₅, --C₃ H₇, ##STR7## q represents an integer selected from 1,2, and 3.

The ratios of ethylene oxide to propylene oxide and butylene oxide which are reacted with the dihydroxy phenol or bisphenol should be carefully controlled. Thus, if the amount of ethylene oxide is excessively high, the elastic properties are impaired. Furthermore, the segment tends to crystallise on stretching, again impairing the elastic properties. On the other hand, the amounts of propylene oxide or butylene oxide used should not be too high, otherwise the thermal stability of the segment becomes unacceptable. For example we have found that for the optimum properties, the ratio of ethylene oxide to propylene oxide and butylene oxide condensed onto the dihydroxyphenol or bisphenol should be within the range 10:1 to 1:20.

It has been found that the melting point of the block copolymer increases with an increase in the molecular weight of the soft section, but decreases with an increase in the weight percent of the soft segment present. Consequently it is advisable that the total amount of ethylene oxide, propylene oxide and butylene oxide which is combined with the dihydroxyphenol or bisphenol group is such that the resulting product has a molecular weight of at least 500 and preferably at least 1,000 but no greater than 10,000. Condensation products having a molecular weight of 1,000 to 5,000 are eminently suitable, enabling the production of block copolymers having a high weight percent of soft segments and also a relatively high melting temperature.

The elastic and work recoveries of fibres melt spun from the copolyesters increases with the weight percent of the soft segments. Hence to achieve acceptable recovery properties, the soft segments must comprise at least 40 weight percent of the coplyester. Elastic recovery values above 90% for the first stretching cycle and around 100% for the fourth stretching cycle are normally obtained when the soft segment comprises at least 55 weight percent of the copolyester. Similarly, work recovery values of at least 20% for the first stretching cycle and at least 90% for the fourth stretching cycle are often achieved when the soft segment comprises at least 45 weight percent of the copolyester.

The elastomeric block copolymers of the present invention are very suitable for converting into tapes, and especially fibres, by melt extrusion using conventional methods. In addition, it has been found that the tackiness observed with yarns spun at low speed decreases with an increase in wind up speed, and those spun in excess of 1 km/min are almost tack-free.

Therefore, according to another aspect of the present invention there is provided a process for the production of an elastomeric fibre in which a block copolyester comprising at least 40 weight percent of soft segments and no more than 60 weight percent of hard segments is melt spun and the resulting fibre is wound up at a speed of at least 1 km per minute, the block copolyester having hard segments comprising at least 70 mole percent of polyethylene terephthalate groups and soft segments which have the structure ##STR8## where (i) X represents a direct link between the phenyl groups, ##STR9## (ii) Y represents a combination of --[--CH₂ --CH₂ --O--]-- (I) with ##STR10## the ratio of (I) to (II)+(III) being within the range 10:1 and 1:20, (iii) m and n each represent an integer, the sum of which corresponds to the segment having a molecular weight of 500 to 10,000,

(iv) R₁₋₈ each represent --H, --CH₃, --C₂ H₅, or --C₃ H₇,

(v) R₉₋₁₀ each represent --H, --CH₃ --C₂ H₅, --C₃ H₇, ##STR11## and (vi) q represents an integer selected from 0, 1, 2 and 3.

Problems arising from any tackiness shown by the melt spun fibres may be reduced or even eliminated by applying a spin finish to them before being wound up. The spin finish may be applied by any suitable conventional means, for instance the fibres may be passed through a bath of spin finish or over a lick roll coated with spin finish, or across a metered spin finish applicator.

The properties of the melt spun fibres, especially the work recovery, may be improved by subjecting them to a hot relaxation treatment, especially a dynamic relaxation treatment. The latter type of treatment increases breaking extension and improves the work recovery after extension cycling to 100%. The degree of improvement of the properties of the fibres is a function of the temperature at which relaxation takes place.

Therefore, according to a further aspect of the present invention there is provided a process for the production of an elastomeric fibre from a block copolyester having hard and soft segments in which the hard segments comprise at least 70 mole percent of polyethylene terephthalate groups, and the soft segments comprise at least 40 weight percent of the block copolyester and have the structure ##STR12## where (i) X represents a direct link between the phenyl groups, ##STR13## (ii) Y represents a combination of --[--CH₂ --CH₂ --O--]-- (I) with ##STR14## the ratio of (I) to (II)+(III) being within the range 10:1 and 1:20, (iii) m and n each represent an integer, the sum of which corresponds to the segment having a molecular weight of 500 to 10,000,

(iv) R₁₋₈ each represent --H, --CH₃, --C₂ H₅, or --C₃ H₇,

(v) R₉₋₁₀ each represent --H, --C₃ --C₂ H₅, --C₃ H₇, ##STR15## and (vi) q represents an integer selected from 0, 1, 2 and 3.

The process comprising melt spinning the block copolyester and winding up the resulting fibre at a speed of at least 1 km per minute, and subjecting the spun fibre to a hot relaxation at a temperature within the range 50° to 220° C. Preferably the hot relaxation is performed continuously, for example by passing the fibre over a feed roll assembly, then over a heated plate or through a heated tube, and finally over an output roll assembly before being wound up or further processed. The output roll assembly operates at a slower speed than the feed roll assembly, the difference in speed being that necessary to produce the desired degree of relaxation. Preferably the temperature of the source of heat is adjusted so that the fibres are heated to a temperature within the range 75° to 200° C. It has been found that temperatures of the order of 150° C. are very suitable for improving the properties of the fibres.

In order to increase the thermal stability of the block copolyesters of this invention a conventional antioxidant may be added. The antioxidant may be added at any convenient time during the manufacture of the polymer or the fibres, or after the production of the fibres, e.g. during the preparation of the soft or hard segments, during the reaction between the two types of segments, or it may be applied as a solution to the spun fibres. Other additives, e.g. light stabilisers, colourants, and delustering agents may be similarly added.

The invention will be further illustrated by reference to the following examples.

PREPARATION OF SOFT SEGMENT COMPONENTS

The soft segments of the block copolyesters of the examples were prepared using the following general method.

The dihydric aromatic compound was charged to the reactor under nitrogen. Sufficient alkali, e.g. potassium or sodium hydroxide or methoxide, to give a final concentration of 0.1% to 0.25% w/w on product was then added and the reactor was stirred and heated to 140° C. whilst a vacuum was applied for 30 minutes. The reactor was then pressured with nitrogen to a pressure of 2.5 Bars and alkylene oxide admitted to give a total pressure of 4.5 Bars. The reaction temperature was controlled between 100° C. and 140° C. whilst the reaction took place, further alkylene oxide being added to maintain the total pressure above 2.5 bars. When the required weight of alkylene oxide had been added and fully reacted, a vacuum was applied to remove traces of volatile material and a neutralising acid, e.g. acetic, phosphoric and adipic acid, was added. Optionally the product was then treated with magnesium silicate e.g. "AMBOSOL" (Nobel Hoechst Chemie) at 110° C.-120° C. and filtered to remove catalyst residues. Prior to discharge "IRGANOX" (Ciba Geigy Ltd) 1010 or 1330, a hindered phenol type antioxidant was added. For dihydric aromatic compounds of melting points above 140° C. a solvent or inert carrier liquid may first be charged to the reactor.

PREPARATION OF POLYMER

The method used to prepare the block copolyesters is illustrated by reference to that used for the preparation of polymer containing 65% of alkoxylate F of examples 21 to 24.

2.37 kg of a low molecular weight polyester formed by the reaction of terephthalic acid and ethylene glycol (1:1.4 TA:EG), 3.9 kg of alkoxylate F (cf Table I) (molecular weight 1900), 12 g (0.20%) of triphenylphosphite and 15 g (0.25%) of the hindered phenol type antioxidant sold by Ciba Geigy Ltd under the name "IRGANOX" 1010, were charged into a reaction vessel at 200° C. The temperature was raised to 240° C. and the low molecular weight polyester allowed to melt under nitrogen. Then 3 g (0.05%) of antimony trioxide as a 10% slurry in ethylene glycol were introduced into the reaction mixture.

The mixture was then stirred and heated under nitrogen to a temperature of 270° C. The vessel pressure was gradually reduced whilst heating, and polycondensation of the resulting product was conducted under a vacuum of less than 1 mm mercury for 3 hours. The clear white polymer obtained had a melting point of 190° C. and an IV of 0.89.

FIBRE SPINNING

The method used for the preparation of fibres from the block copolyesters is illustrated by reference to that used for the preparation of fibres of Examples 21 to 24.

Dried polymer chip containing 65% of alkoxylate F of Table I, was melted in a screw extruder, whose temperatures were set at 146° C. (feed section), rising to 203° C. (extrusion), the molten polymer was then passed through a filter bed of 30 g of 30 grade alumina and 10 g of 60 grade alumina, and finally extruded at a rate of 5.1 g/minute through a spinneret with 7 holes of 380μ diameter. The yarn was passed through an air-quench zone, over a spin finish applicator, where it was lubricated with about 5% of a silicone-based finish, and wound up at 1.5 km/min. The resulting yarn was not tacky and had the properties given in Table 2, Cell 22.

TAPE SPINNING AND DRAWING

The method used for the preparation of tape from the block copolyesters is illustrated by reference to that used for the preparation of tapes of Example 29 from the polymers used in Examples 18 to 20.

The polymer chip containing 65% of alkoxylate C of Table I, was melted in a screw extruder, whose temperatures were set at 150° C. (feed section), rising to 203° C. (extrusion), the molten polymer was passed through a filter bed of 40 g of 30 grade alumina, and finally extruded at a rate of 1.5 g/min through a spinneret with a 0.25 mm×10 mm slot. The tape was passed through an air quench zone, and was then wound up at 1 m/minute. It was finally drawn six fold at 6 m/minute and then allowed to relax by winding it at a final speed of 2 m/minute. The properties of this tape are given in Table 4.

TEST METHODS Melting Point

Samples of about 10 mgs of chip were heated under nitrogen in a Perkin-Elmer Differential Scanning Calorimeter (Series 7) to raise the temperature by 20° C. per minute. The quoted melting point is the peak of the melting endotherm.

Intrinsic Viscosity

The flow times for 0.1-0.5 wt % solutions of polymer chip in phenol/tetrachloroethane (40/60 w/w) at 25° C. were compared to that of the pure solvent, and the viscosity calculated in the normal manner.

Tenacity and Extension

The sample of yarn was first allowed to equilibrate overnight in a standard atmosphere (65±2% RH and 20±2°±2° C.), and then it was placed between the jaws of an Instron Tensile Tester (Model TM-M), set with a 5 cm gap. The sample was extended at a rate of 25 cm/min till it broke, and the results calculated from a calibrated chart running at 50 cm/min.

Elastic and Work Recovery

The sample of yarn was conditioned as above and tested with similar Instron settings. When it had been extended by 100%, the Instron cross-head automatically reversed and returned to its starting position. After a 30 second delay, the procedure was repeated three times. Only the results from the first and fourth cycles are quoted in the Tables. ##EQU1##

The elastic recovery was obtained by direct measurement along the extension axis of the chart, while the work recovery was obtained by weighing the areas under the curves. The slack in the yarn after the first and subsequent cycles was not taken up before retesting. Thus the yarn was not stretched the full 100% during the 2nd, 3rd and 4th cycles.

The following examples describe the properties of fibres melt spun from block copolyesters in which the soft segments were derived from the following compounds: ##STR16##

                  TABLE 1                                                          ______________________________________                                         Structural                                                                               Alkylene oxide units                                                 Reference (a + d)      (x + y)  (b + c)                                        ______________________________________                                         A         14            3       6                                              B         10           10       9                                              C         16           10       9                                              D         20            3       0                                              E         19           10       0                                              F         25           10       0                                              ______________________________________                                    

EXAMPLES 1-26

Block copolyesters, whose composition and properties are given in Tables 1 and 2, were melt spun using the general conditions described above, and the properties of the resulting fibres wound up at various speeds are given in Table 2.

                                      TABLE 2                                      __________________________________________________________________________            Soft          WIND UP                                                           SEGMENT                                                                               Tm    SPEED TENACITY                                                                              EXTN                                                                               ELASTIC RECOVERY                                                                            WORK RECOVERY               EXAMPLE                                                                               TYPE                                                                               % WT                                                                               °C.                                                                        IV KM/MIN                                                                               CN/TEX %   CYCLE 1                                                                              CYCLE 4                                                                               CYCLE                                                                                CYCLE                 __________________________________________________________________________                                                              4                     1      A   40  221                                                                               0.79                                                                              1.0   4.9    266 76    89     19    67                    2                    2.0   8.2    164 72    89     14    71                    3      A   45  212                                                                               0.85                                                                              1.0   4.8    319 84    92     24    73                    4      A   50  206                                                                               0.86                                                                              1.0   5.4    248 85    97     25    77                    5      A   55  196                                                                               0.76                                                                              1.0   4.9    179 88    99     19    88                    6      B   50  217                                                                               0.78                                                                              1.0   4.0    282 88    96     30    77                    7                    2.0   9.6    120 86    97     --    --                    8      C   50  222                                                                               0.92                                                                              1.0   6.3    272 85    98     24    78                    9                    2.0   7.6    141 84    97     17    79                    10     C   55  213                                                                               0.85                                                                              1.0   4.9    322 90    99     24    80                    11                   2.0   7.4    119 89    97     16    79                    12     C   60  205                                                                               0.96                                                                              1.0   4.6    270 93    100    25    84                    13                   2.0   7.2    140 93    100    20    91                    14     E   50  214                                                                               0.95                                                                              1.0   8.0    295 --    --     --    --                    15                   1.5   10.1   237 82    97     17    80                    16     F   50  220                                                                               0.93                                                                              1.0   5.0    291 --    --     --    --                    17                   1.5   9.1    226 86    99     22    86                    18                   1.0   3.2    174 90    112    27    102                   19     C   65  190                                                                               0.84                                                                              1.5   4.5    136 94    115    21    96                    20                   2.0   5.5     99 92    122    20    109                   21                   1.0   5.7    240 94    109    21    100                   22     F   65  190                                                                               0.89                                                                              1.5   7.0    207 94    106    22    99                    23                   2.0   9.7    165 97    106    20    95                    24                   3.0   11.3   124 90    111    24    106                   25     C   67  180                                                                               0.92                                                                              1.0   --     --  93    100    27    89                    26         65  189                                                                               0.96                                                                               0.25 --     --  94    99     26    90                    __________________________________________________________________________

EXAMPLES 27-28

Elastomeric fibres were produced by melt spinning the polymer used for Examples 18-20 and winding up the fibres at a speed of 2 km per min. They were then heat relaxed by passing them over a drawing machine comprising a hot plate located between a feed roll assembly and a draw roll assembly. The former was run at a speed of 3 meters per minute and the latter at 2 meters per minute, i.e. the fibres were allowed to relax approximately 33%. The properties of the resulting fibres are given in Table 3.

                  TABLE 3                                                          ______________________________________                                                                  Elastic   Work                                        Ex-  Relaxation Breaking Recovery (%)                                                                             Recovery (%)                                am-  Temperature                                                                               Exten-   Cycle Cycle Cycle Cycle                               ple  (°C.)                                                                              sion (%) 1     4     1     4                                   ______________________________________                                         27   --          99      92    122   20    109                                 28   100        265      85     95   45     95                                 ______________________________________                                    

EXAMPLE 29

The properties of the tape produced by spinning, drawing, and relaxing at ambient temperature the polymer containing 65% of alkoxylate C of Table I, at a final speed of 2 m/minute are given in Table 4.

                  TABLE 4                                                          ______________________________________                                         Tenacity                                                                               Extn    Elastic Recovery                                                                              Work Recovery                                   CN/Tex  %       Cycle 1  Cycle 4 Cycle 1                                                                               Cycle 4                                ______________________________________                                         1.7     434     92       99      66     90                                     ______________________________________                                    

The following examples describe the properties of fibres melt spun from block copolyesters in which the segments were derived from the following: ##STR17##

The elastomeric polymers were prepared and melt spun using the general conditions previously described, and their properties are given in Table 3.

                                      TABLE 3                                      __________________________________________________________________________                    Wind-up         Elastic                                                                               Work                                     Soft Segment                                                                               Tm Speed                                                                               Tenacity                                                                            Extension                                                                            Recovery                                                                              Recovery                                 Example                                                                             Type                                                                              % Wt                                                                               °C.                                                                        Km/min                                                                              CN/TEX                                                                              %     C1 C4  C1 C4                                    __________________________________________________________________________     30   G  65  213                                                                               1.5  3.4  188   93 107 21 91                                    31   H  65  209                                                                               1.5  5.4  177   91 105 24 91                                    32             2.0  8.0  126   100                                                                               108 24 89                                    33   I  65  221                                                                               1.5  7.1  134   93 104 22 88                                    34             2.0  6.2  143   97 107 19 91                                    35   J  65  183                                                                               1.5  2.9  128   94 108 20 89                                    __________________________________________________________________________ 

We claim:
 1. An elastomeric block copolyester comprising hard and soft segments, wherein the hard segments comprise at least 50 mole percent of polyethylene terephthalate groups, and the soft segments comprise at least 40 weight percent of the block copolyester and have the structure ##STR18## where (i) X represents a direct link between the phenyl groups, ##STR19## (ii) Y represents a combination of --[--CH₂ --O--]-- (I) with ##STR20## the ratio of (I) to (II)+(III) being within the range 10:1 and 1:20, (iii) m and n each represent an integer, the sum of which corresponds to the segment having a molecular weight of 500 to 10,000,(iv) R₁₋₈ each represents --H, --CH₃, --C₂ H₅, or --C₃ H₇, and (v) R₉₋₁₀ each represent --H, --CH₃, C₂ H₅, C₃ H₇, ##STR21##
 2. An elastomeric block copolyester according to claim 1, wherein the soft segments comprise at least 60 weight percent of the copolyester.
 3. An elastomeric block copolyester according to claims 1 or 2 wherein the hard segments are formed entirely or polyethylene terephthalate groups.
 4. An elastomeric block copolyester according to claim 3 wherein the soft segment has a molecular weight within the range 1,000 to 5,000.
 5. An elastomeric copolyester according to claim 1, wherein the soft segment comprises up to 75 weight percent of the copolyester. 